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Disclosure to Promote the Right To Information

Whereas the Parliament of India has set out to provide a practical regime of right to information for citizens to secure access to information under the control of public authorities, in order to promote transparency and accountability in the working of every public authority, and whereas the attached publication of the Bureau of Indian Standards is of particular interest to the public, particularly disadvantaged communities and those engaged in the pursuit of education and knowledge, the attached public safety standard is made available to promote the timely dissemination of this information in an accurate manner to the public. 7"#1 &" 8+9&"), 7:1 &" 8+9&")
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/0)"1 &2 324 #' 5 *)6

Step Out From the Old to the New
Jawaharlal Nehru

IS 7634-3 (2003): Plastics Pipe Selection, Handling, Storage and Installation for Potable Water Supplies - Code of Practice : Part 3 - Laying and Jointing of UPVC Pipes [CED 50: Plastic Piping System]

Invent a New India Using Knowledge

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Satyanarayan Gangaram Pitroda

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Knowledge is such a treasure which cannot be stolen
Bhart+hariN,ti-atakam

IS 7634 (Part 3) :2003

qJ1-lq

Indian Standard PLASTICS PIPES SELECTION, HANDLING, STORAGE AND INSTALLATION FOR POTABLE WATER SUPPLIES CODE OF PRACTICE
PART 3 LAY[NG AND JOINTING OF UPVC PIPES

(First Revision )

ICS 83. 140.3;91 .140.60

0 BIS 2003

BUREAU
MANAK

OF
BHAVAN,

INDIAN

STANDARDS
ZAFAR MARG

9 BAHADUR SHAH NEW DELHI 110002

April 2003

Price Group 10

Plastic Piping System Sectional Committee,

CED 50

FOREWORD This Indian Standard (Part 3) (First Revision) was adopted by the Bureau of Indian Standards, after the draft finalized by the Plastic Piping System Sectional Committee had been approved by the Civil Engineering Division Council. The preparation of a code of practice for plastics pipe work for potable water supplies was taken up to make avai Iable comparative properties of different types of plastics pipe. Additionally, it would give guidance for their selection for different situations arising in practical usage and also to recommend sound practices for the installation, jointing and testing of such pipe systems. It was hoped that the code would assist in greater application of plastic pipes. Part 3 of the standard covered laying and jointing of unplasticized polyvinyl chloride (UPVC) pipes. The other parts published Part I Part 2 so far in the series are:

Choice of materials and general recommendations Laying and jointing polyethylene (PE) pipes

III the formulation of the original standard, due weightage was given to international co-ordination among the stzindards and practices prevailing in different countries in addition to relating it to the practices in the field in this country. This was met by deriving assistance lrom BS : CP 312: Part 2: 1973 Code of practice for plastics pipe work for the conveyance of fluids under pressure issued by the British Standards Institution. With the advent of globalization and the likelihood of the influx of foreign competition, the committee felt that this standard should be brought even more in line with revised international standards. The need was also felt to give a mot-c comprehensive treatment to the entire area of handling, transportation, storage, installation and very importantly, the testing of pipelines prior to their commissioning. For this purpose, assistance was drawn from the European Standard prEN 1452-6: 1994 Plastics piping systems for water supply Unplasticized poly vinyl chloride (UPVC) Part 6: Recommended practice for installation as well as other literature. .Further, the sections on heat application method have been altogether deleted from this revision, as it is felt that this is an operation requiring considerable skill by trained personnel and therefore is not recommended for use by normal installation teatns in the field. The composition of the Committee responsible for formulation of this standard is given in Annex A.

IS 7634 (Part 3) :2003

Indian Standard PLASTICS PIPES SELECTION, HANDLING, STORAGE AND INSTALLATION FOR POTABLE WATER SUPPLIES CODE OF PRACTICE
PART 3 LAYING AND JOINTING OF UPVC PIPES

(First Revision )
1 SCOPE 1.1 This code of practice (Part 3) gives guidance for the proper methods of laying and jointing of unplasticized polyvinyl chloride (UPVC) pipe work for potable water supplies (water mains and services buried in ground and for the conveyance of water above ground for both outside and inside buildings). 1.2 This standard is applicable for cold water supplies upto and including 45C only. Appropriate de-rating factors apply as per IS 4985:2000 Unplasticized PVC pipes for potable water supplies Specification (third revision). 1.3 This standard does not purport to give guidelines for designing and dimensioning of pipelines. 1.4 Local bye-laws shall be strictly observed whenever used for municipal water distribution. 2 REFERENCES The following standards contain provisions, which through reference in this text, constitute provisions of this standard. At the time of publication editions indicated were valid. All standards are subject to revision and parties to agreements based on this standard are encouraged to investigate the possibility of applying the most recent editions of the standards indicted below: IS No. 4985:2000 Title Unplasticized PVC pipes for potable water supplies Specification (third revision) Specification for rubber sealing rings for gas mains, water mains and sewers Solvent cement for use with unplasticized polyvinylchloride plastics pipe and fittings TECHNIQUES (hard), in-factory cut lengths. Pipes are supplied with one of the following four end conditions: a) b) c) d) Plain end, for jointing by means of separate couplers, including mechanical joints, Integral socket on one end, fir solvent cement jointing, Integral socket on one end for jointing elastomeric sealing rings, and with

Threaded, for jointing with threaded couplers.

3.1.1 Satisfactory jointing plays an important role in successful performance of these pipes, Commonly used joints are as follows: a) b) c) d) e) ~ Solvent welded joints, Integral elastomeric Mechanical Flanged joints, Screwed or threaded joints, and Union coupled joints. Joints sealing ring joints, joints, compression

3.2 Solvent Welded

3.2.1 These are permanent in nature and can withstand axial thrust (end-load bearing). This technique is used with plain ended pipes with couplers, for pipes with integral sockets as well as with injection moulded fittings (see Fig. 1), 3.2.2 Pipes and fittings are manufactured to certain tolerances to provide for small variations in the extrusion, moulding and socket processes and are not exact in size. 3.2.3 Solvent Cement Consists essentially of a solution of vinyl chloride polymer or copolymer dissolved in a suitable volatile mixture of organic solvents. The solvent constituents soften the mating surfaces, which diffuse into one another to form a cold weld. 3.2.3.1 Specljlcation Solvent cement shall conform to all the requirements of IS 14182. 1

5382:1985

14182:1994

.3 JOINTING 3.1 General

Unplasticized PVC pipes are made by a continuous extrusion process and are generally available as rigid

IS 7634 (Part 3) :2003

..

LPVC

COUPLER PVC PIPE 1

FIG.

SOLVENT \ WELDED JOINT

1 PVC SOLVENT WELDED JOINT

3.2.3.2 Selection Solvent cement is available in three grades of viscosity as given below to cover a range of pipe sizes from 20 mm to 630 mm. Sufficient solvent cement shall be applied so that a wet-film thickness adequate enough to fill a gap in a pipe joint is formed. Selection is also dependent on the climatic conditions prevalent at the site. Pipe Size Minimum Wet Film ~ ~ .Thickness MPa.s cp mm 90 0.15 Regular bodied 90 500 0.3 Medium bodied 500 Heavy bodied 1600 1600 0.6 Cement Type Minimum Viscosity

cutting must not raise a burr or ridge on the cut end of the pipe. Failure to remove the ridge will result in cement in the fitting or socket being scraped away from the jointing surfaces, leading to a dry joint with probability of join; failure, Remove-all bums and ridges with a deburring knife, file, or abrasive paper (see Fig. 2). 3.2.4.2 Chamfering Provide an approximately 2 mm wide, 15 chamfer on pipe ends. A chamfer prevents the cement film from being wiped off into the interior of the socket during assembly. 3.2.4.3 Dqjt test

mm upto 50 63 to 160 Above 200

Before applying cement, insert the pipe end into the socket of the next pipe or fitting to check that interference occurs at about ~ to ~ of the socket depth. When the pipe and the socket are at their extreme tolerances, the pipe can bottom (travel full y into) in the socket. In such a case, it should be a snug fit. A loose or wobbly fit will result in joint failure. Another pipe end or the socket should be selected until these conditions are fulfilled. Mark the insertion depth on the pipe end with a felt tip pen or marker. 3.2.4.4 Cleaning Surfaces to be joined must be free of dust, dirt, oil, moisture and other foreign material. Wipe clean with a dry cloth. If this is not sufficient, use a chemical (such as dichloro-methane, methyl ethyl-ketone or mechanical cleaner). With chemical cleaners, observe safety precautions. Ketones are inflammable. 3.2.4.5 Application of cement

Medium bodied and heavy bodied cements may be used for smaller pipe sizes than that shown in the table above. The reverse does not hold good. 3.2.3.3 Storage PVC solvent cement should be stored in a cool place except when actually in-use at the site. The cement has a limited shelf life when not stored in hermetically sealed containers. HDPE screw top containers are not considered hermetically sealed. The cement is not suitable for use if it exhibits an appreciable change from the original viscosity, or if a sign of gelation is apparent. Addition of thinners is not recommended for restoring the original viscosity. 3.2.4 Procedure 3.2.4.1 Cutting Pipes are supplied with square-cut and de-burned ends. However, if pipes need to be cut to smaller lengths, use a fine-toothed hand saw and a mitre box or a power saw with wood-working blades, with a Suitable guide. The 2

PVC solvent cement is quick drying, therefore it shall be applied as quickly and carefully .as possible and in consistence with good workmanship. For larger sizes, it is advisable for two workers to work simultaneously on the pipe and socket. The surface temperature of the

IS 7634 (Part 3) :2003

ILING

DE8URI?ING

b
Recommended setting times, A4in h 1 2 4 6 and commissioning

FIG.

2 PIPE CUTTING AT SITE

mating surfaces should be above OC but should not exceed 45C. Water can be used to cool the surfaces, but these should be wiped thoroughly dry before application of cement. Dip the applicator brush in the solvent cement and apply a liberal coat of cement to the end of the pipe upto the insertion depth. Apply a uniform thin coat of cement inside the socket, working axially from the inside of the socket to the outside. Do not apply any cement on the shoulders of the socket (socket-to-pipe transition area). Care should be taken not to apply excess cement inside the socket. Excess cement m the socket will be pushed further into the pipe during assembly and cause the pipe to soften and weaken at that point. Hot and dry climates generally require slightly thicker coatings of solvent cement. In climates with large differences between day and night temperatures, it is advisable to make joints early in the morning or in the evening when it is cooler. Thus, the joints are prevented from being pulled apart if the pipes contract. 3.2.4.6 Within 20s after the last application of solvent cement, insert the pipe into socket in a single steady and every controlled but forceful action. Press it in fully until it bottoms. No hammer blows should be used. If there is any sign of drying of the cement coat before insertion; the surface should be re-coated, avoiding application of excess cement in the socket. Once the insertion is complete, hold in place for 1 min without shifting the pipe in the socket. 3.2.4.7 For large diameter pipes, two or more workers may be needed for this operation. Mechanical equipment such as levers and winches maybe used. Care shall be taken to ensure that force is not transmitted to previously made joints. Until the cement is set, the pipe must be prevented from backing out of the socket. 3

3.2.4.8 Immediately after assembly, wipe the excess solvent cement from the pipe at the end of the socket. A properly made joint will have a uniform bead around its entire perimeter. Any gaps in this bead may be indicative of an improper joint due to insufficient cement or the use of a lighter-bodied cement than the one recommended. 3.2.4.9 Setting times Joints should not be handled until the requisite setting time has elapsed. Recommended setting times are a function of the ambient temperature at the job site as given below: Temperature c 15t040 5to15 -5 to 5 -20 to -5 3.2.4.10 Installation

After the setting time has elapsed, the pipe may be handled carefully for installation. Pressure testing may be carried out only after a curing period of 24 h. 3.3 Integral Elastomeric Sealing R@ Joints

Pipes are cut to length and bell socket in-line, to form a groove for the elastomeric sealing ring, and supplied in nominal lengths. Couplers and bends fabricated out of UPVC pressure pipes are likewise socket. 3.3.1 Elastomeric sealing ring joint consists of an elastomeric sealing element located in the groove in the socket formed integrally with the pipe or fitting. The sealing element (sealing ring) is automatically compressed to form a pressure tight seal when the spigot of the pipe is inserted into the socket. 3.3.2 These joints are non-end load bearing and it is

IS 7634 (Part 3) :2003 essential to ensure the probability of joint separation due to axial thrust. Joint separation can be prevented in below ground applications by incorporating concrete anchor blocks at ap~ropriate places. In above ground applications, anchor blocks must be provided (see 6.4). Where large diameter pipes operating at high pressures are involved, axial thrusts of several tonnes can be developed. 3.3.3 In order to meet water quality and biodegradation requirements, elastomeric sealing rings are usually made from synthetic materials like ethylenepropylene- diene (EPDM) copolymer, styrenebutadiene rubber (SBR) or a combination of synthetic and natural rubber. The material should conform to 1S 5382. 3.3.4 Procedure 3.3.4.1 Pipes are supplied with the spigot end chamfered. However, if pipes have to be shortened for any reason, preparation of the ends will be necessary before assembly. 3.3.4.2 Cutting of pipes, if required, must be done on a jig to ensure that the cut is square to the axis of the pipe. It is recommended that the pipe be marked around the entire circumference prior to cutting. The pipe ends must be chamfered at an angle of 15 with a medium grade tile and de-burred. (see Fig. 2). 3.3.4.3 Clean the spigot end of the pipe upto the insertion depth (depth of the corresponding socket). Remove all traces of mud, dirt, grease and gravel. Do not use any chemicals or solvents for cleaning. For stubborn areas of dirt. a very fine grade of emery or sand paper can be used lightly. Wipe the pipe with a clean cloth moistened with water and allow to dry completely. 3.3.4.4 Clean the inside of the socket. Remove all traces of mud, dirt, grease and gravel. Do not us+ any chemicals or solvents for cleaning. For stubborn areas of dirt, a very fine grade of emery or sand paper can be used lightly. Wipe the inside of the groove with a damp cloth and allow to dry completely. 3.3.4.5 Mark the insertion depth on the spigot of the pipe, if not already applied by the manufacturer. The insertion depth is equal to the depth of the socket of the pipe, measured upto the end of the parallel portion of the socket (excluding the shoulder). This distance is marked on the spigot (excluding the chamfer) with an indelible felt-tip marking pen. 3.3.4.6 Insert the elastomeric sealing ring into the groove. Rings to be used are system specific and shall be those supplied by the manufacturer for his own system. Form the ring into a heart shape by pinching a portion of the ring from the inside (see Fig. 3). Insert into the socket and release to seat into the groove. Ensure proper seating of the ring in the groove. If the ring is wrongly inserted it will lead to leakage. It may also dislocate completely during assembly. Follow instructions of the manufacturer. 3.3.4.7 Apply lubricant to the outside of the spigot (consult the manufacturer). The lubricant should cover the entire surface of the spigot for at least half the insertion depth, starting from the end of the pipe. The lubricant used should not have any detrimental effect on the pipe, fittings or the elastomeric sealing ring and shall not be toxic, shall not impart any taste or odour to the water or encourage growth of bacteria. Do not use oil-based or solvent-based lubricants. 3.3.4.8 Align the socket and spigot correctly in the horizontal and vertical planes. Ensure that no sand or dirt adheres to the lubricated surfaces of the pipe. 3.3.4.9 Insert the spigot end carefully into the socket. Place a firm wooden block against the other end of the pipe and, using a crow-bar as a lever, push home the spigot upto the insertion depth mark (see Fig. 4). For larger sizes of pipe, the use of a jointing jack may be helpful. The jack can also be used to extricate a pipe from a socket.

FIG.

3 SEALING RING JOINT ASSEMBLY \ 4

IS 7634 (Part 3) :2003 3.4 Mechanical Compression Joints threads. Threaded pipes shall not be subjected to a pressures exceeding two-thirds of the rating for unthreaded pipes. 3.6.1 To obtain a good thread, it is essential to ensure that: a) Die holder is fitted with a guide of the correct size. The guide must be properly screwed down so that the two halves of the die are flush with the face of the holder. Die is not blunt. Two halves of the die are adjusted so that they are seated squarely in the holder and are equidistant from the sides of the holder. Observe the gaps on either side. There are no sharp edges on the end of the pipe. Provide a light chamfer with the edge of a sharp knife. Die holder is carefully slid over the pipe and the two halves of the die adjusted with the fingers so that the first threads seat lightly on the pipe. Pipe must be properly centered. Now tighten the adjusting screws M turn with a spanner. Thread is cut slowly and that after every %turn, the die is turned back 4 turn. Entire thread is cut in four equal passes.

These are commonly separate fittings made from UPVC or metal and can be in the form of a coupler for connecting pipes and tittings of the same material and of the same dimensions, or as an adaptor for connecting components of different materials andlor dimensions. Generally compression fittings consist of four main elements: body, elastomeric scaling rings, backing (compression) rings and bolts. Both pipe ends should bc clean and free from damage before assembly is begun. Each element is positioned on the pipe separately, centred over the joint and the sealing rings compressed between the body of the fitting and the pipe by tightening the backing rings. Bolts should not be over tightened and the manufacturers recommendations followed at all times (see Fig. 5). 3.5 Flanged Joints These are used for jointing of UPVC pipes to other pipes, fittings, valves and vessels made from dissimilar materials, for example metals. The joint is made by compressing a gasket or elastomeric sealing ring between the mating surfaces of the flanges. Detailed flange designs can vary considerably. Figure 6 and Fig. 7 show two types of flanged joints. 3.6 Screwed or Threaded Joints

b) c)

d)

e)

0 g)

These are similar to the joints used with metal pipes. If the pipe has to be joined by screw threads, only thick walled pipe should be used and cut with taper threads. Some manufacturers supply pipes with factory cut

Automatic threading machines may also be used. Follow the instructions of the manufacturer. 3.6.2 Short pieces of thick-walled pipe maybe threaded at one end and solvent cemented onto normal walled pipe at the other to make the connector pieces to screwed metal fittings. This system may be used for pipes upto 50 mm outside diameter. 3.6.3 No tape or paste shall be used for jointing. The joint shall be made to firm hand tightness using only strap wrenches.

EL ASTOMORIC (RUEH3ER) SEALING RING

INSERTION .OEPTH MARK ON SPIGOT

ASSEMBLED JOINT PUSH

3.6.4 There is no well defined increase in tightness at assembly as there is with metal fittings. These joints can therefore very easily be overstrained. 3.6.5 Injection moulded threaded joints are used for jointing PVC to metal pipes. Injection motdded threads are less notch sensitive than cut threads. 3.6.6 PVC to metal connections with threaded joints shouldbe made with the PVC as the male components of the joint. PVC as the female component may be used only when specific arrangements are made to prevent over tightening or where both the threads are of parallel form and the fluid seal is made by a separate ring or gasket. A typical illustration of this is shown in Fig. 8.

Fi~. 4

BAR

AND BLOCK ASSEMBLY

1S 7634 (Part 3) :2003

.. , \\\\\\\\\\ \

I
1
d

-.

-.
&

II
.- ..

II

FIG.

5 MECHANICAL COMPRESSION JOIN-I

METALLIC BACK-UP FLANGE PVC VANSTONE OR FIPI

P IPE SOLVENT WELDED OR PVC FLANGED TAIL PIECE

. . ; : .. _. A:! b
A METAL PIPE WITH
G             D  7   

.?

a :

.,. ,x,

&\

-d&l

~NUT
FIG.

AND

BOLT

6 FLANGED JOINTS WITH PVC

BOLT AND NUT PVC PIPE SOLVENT /RLJBBER GASKET

II

-+

I ~~ pvc FLANGED TAIL PIECE

FIG. 7 FLANGE JOINTS (JOINTING PVC

L~oNvEN,,oNAL

plpE

* .

(WELDED OR SCREWED TO METALLIC FLANGE)

PIPES AND OTHER CONVENTIONAL PIPES USING PVC

FLANGED TAIL PIECE)

IS 7634 (Ptirt 3)-: 2003 3.6.7 While connecting metallic water taps to the PVC pipes in domestic plumbing, it is recommended to use a metallic coupler to the tap and then connect the same to the PVC pipe using injection moulded threaded joints. The metallic part alone is supported and not the PVC. The unsupported length from the face of the wall should not be more than 100 mm for satisfactory operation and a strong coupling should be provided on the face of the wall at the point of overhang. For any repairs on the tap, the tap should be removed from the metal coupler to avoid working on it it?-situ. A typical illustration of such a connection is shown in Fig. 9. 3.7 Union Joint rhis is a form of flanged joint, but the faces are held together by a screwed connection. A composite metal and PVC socket union is a very satisfactory method of jointing PVC to screwed metaliic fittings. A typical illustration of union is shown in Fig. 10. 3.8 Service Connections 3.8.1 Both metal and plastic saddles are available for the off take of service connections from larger bore pipes (50 mm diameter and above). One type of saddle consists of a half round moulded unplasticized PVC section which is solvent cemented to the pipe surface. The outside of the PVC section has a boss onto which the service connection may be screwed. Another type consists of two half round sections of metal or PVC which are bolted together or held around the pipe by wedge grips. A seal is formed between the saddle and the pipe by a rubber O-ring compressed between the

PVCw~~:E:OLVENT

METALUC PIPE SCREWED END) K

~ Pvc

T~READ~D

ME~ALLlc

T~REfUJE13

ADAPTOR (MALE)

COUPLER

(FEMALE )

FIG.

8 JOINTING PVC PIPE TO CONVENTIONAL PIPE USING THREADED JOINTS

PVC PIPE SOLVENT

COUPLER

COUPLER

TAP

FIG. 9 CONNECTION OF PVC PIPE TO METALLIC WATER TAPS

IS 7634 (Part 3) :2003

a) UNION COUPLER

b) UNION ADAPTER

c) ADAPTER

BUSH

FIG.

10 TYPES OF UNION JOINTS

pipe and the under surface of the section. The service connection is taken from a boss on the upper section. 3.8.2 Conventional equipment for tapping under pressure may be used with these service connections using a special trepanning cutter to pierce the pipe wall. Some ferrules have self contained cutters for this purpose. Ferrules should not be screwed directly into un-reinforced pipes without the introduction of a reinforcing saddle piece. A typical illustration of union is shown in Fig. 11. 4 TRANSPORT, PIPES HANDLING AND STORAGE OF

4.1 Transport 4.1.1 When transporting pipes, flat bed vehicles should be used. The bed should be free from nails and other projections. When practical, pipes should rest uniformly on the vehicle over the whole length (see Fig. 12). 4.1.2 The vehicles should have side supports approximately 2 m apart and the pipes should be secured effectively during transport. All posts should be flat with no sharp edges. 4.1.3 When loading spigot and socket pipes, the pipes should be stacked on the vehicle so that the sockets do not take excessive loads. 4.1.4 Where pipes overhang the vehicle, the amount of overhang should not exceed 1m. 8

Became UPVC pipes are durable and light, they are more 1ikcly to be mishandled. Care should be taken to ensure that pipes are not damaged during handling, storage and transport.

IS 7634 (Part 3) :2003

FERRULE

f%--.,,.,,,, t
PVC THREADED SADDLE OUTLET (FEMALE) SEALING RING GASKET

PVC

PIPE

..

. +

7 4~ / \\

/4/
Tic

PYC SERVIC, SADDLE

FIG. 11 FERRULE CONNECTION USING SERVICE SADDLE

4.1.5 High stiffness pipes should be -placed at the bottom of the load and low stiffness pipes at the top. 4.1.6 Care should be taken to avoid positioning the pipes near to any exhaust systems or any other potential hazards such as diesel oil, paints or solvents. 4.1.7 Pipes should be inspected prior to off-loading. 4.1.8 When pipes are transported in bundles, the bunci]es should be secured effectively and off-loaded as described in 4.3. 4.2 Handling 4.2.1 UPVC pipes should be handled keeping in mind that they are made of plastic and are also susceptible

to damage if mishandled. They should not be thrown, dropped or dragged. Single pipe of upto 250 mm can be lifted by two men without difficuhy (see Fig, 13, 14 and 15). 4.2.2 Mechanical lifting equipment used for lifting pipes and pipe bundles should not damage the pipe. Fork-lift forks should be flat and protected. Cranes should have spreader bars. No wire ropes, chains or hooks should be used. Slings should be made of rope or webbing 7 to 10 cm wide (see Fig. 16). 4.2.3 If pipes have been telescoped the inner pipes should be removed separately. for transporting, first and stacked

x
YoJ-INCORRECT WAY TO LOAD PIPES CORRECT WAY TO LOAD PIPES
FIG.

12 TRANSPORTATION
9

IS 7634 (Part 3) :2003 4.2.4 Resistance to impact is reduced in cold weather. Extra care needs to be taken at temperatures around OC. At temperatures below 15C, special instructions from the manufacturer should be obtained. 4.3 Storage 4.3.1 Pipes should be stacked on a surface flat and free from sharp objects, stones or projections in order to avoid deformation or damage. Ends of pipes should be protected from abrasion and chipping. 4.3.2 The pipes should be supported evenly over their whole length. The bottom layer of the stack should be supported on wooden battens of uniform size, at least 50 mm wide and placed not more than 2 m apart. The sockets should not bear on the ground (see Figs. 17 and 18). 4.3.3 Pipes of different diameters and different pressure classes should preferably be stacked separately. 4.3.4 Factory packed pipes should packed in bundles with timber battens at minimum three places. These should not be unpacked until required for use.

f
I

.V

WRONG
FIG,

RIGHT

13 HANDLING

FIG.

14 HANDLING AND TRANSPORTATION

FIG. 15 MANUAL HANDLING

10

IS 7634 (Part 3) :2003

NON- METALLIC WIDE BAND WEBBING --

1[

WEBBING POSITION OUTSIDE TIMBER EIATTENS~

-w _ K~

FIG.

16 MECHANICAL LIFTING

4.3.5 Bundles in depots should be stacked no more than three units or 2 m high, whichever is lower, as shown in Fig. 19. 4.3.6 On the site, bundles should be stacked no more than two units or 1 m, whichever is lower.

4.3.7 Timber framed bundles should be stacked timber to timber. 4.3.8 It should be necessary to store pipes loose or if they are received loose, care should be taken to see that each layer of the stack lies alternatively with the sockets on opposite ends of the stack. The sockets of

SOCKETED PIPES STI)RED . WITH SOCKETS AT ALTERNATi-iiiDi m e f MAX. STACK HEIGH 7 LAYERS OR 1.5m j / ~MAxiMuM

/////i

STOUT TIMBER BEAR ERS

ax. l-5m
ENTRES

.--~ WIDTH=3Om

FIG.

17 STACKING IN DEPOT

FIG.

18 STACKING AT SITE 11

IS 7634 (Part 3) :2003 each pipe must project sufficiently for the pipes to be supported correctly along the whole length (parallel stacking) [see Fig. 20(A)]. 4.3.9 The sides of the stack must be supported with timber battens to prevent stack collapse. The side supports should be spaced not more than 3 m apart. The width of the bottom layer should not exceed 3 m. 4.3.10 Alternatively, pipes can also be stacked with adjacent layers 1 ying at right angles to each other (cross stacking), while observing that the sockets lie as stated in 4.3.8 [see Fig. 20 (B)]. 4.3.11 Stack height should not exceed 1.5 m in depots and stores or 1 mat construction sites (see Fig. 17 and 18). 4.3.12 Prolonged exposure of the pipes to sunlight must be avoided. Pipes must be protected from ultra-violet light (sunlight), which would otherwise cause discoloration and can reduce the impact strength of the pipe. However, resistance to internal water pressure is not reduced. Suitable protection by a free-venting cover (canvas tarpaulin or polyethylene sheeting) is

fm 7

2.25m

1-

1-

T
ADDITIONAL SUPPORT BATTENs
FIG.

2m Max.

B
19 STACKING OF BUNDLED PIPES

=1s
20A Parallel Stacking

206 Cross Stacking

FIG.

20 STACKING OF PIPES 12

IS 7634 (Part 3) :2003 recommended if the total exposed exceed 4 weeks (see Fig. 2 1). time is likely to violet content. They should not be stored in a room with any equipment capable of generating ozone, for example mercury vapour lamps, high voltage electrical equipment which may give rise to electrical sparks of silent electrical discharge. The seals should be stored in a relaxed condition free from tension, compression or other deformation.-For instance, they should not be suspended from any part of the circumference. The seals should be maintained in a clean condition; they should not be removed from their containers until shortly before use. Shelf-life of scalings rings depends on the material of manufacture. Consult the manufacturer. While handling, care should be taken that they are not abraded, scratched or nicked and that the sealing lips are not damaged in any way. 6 UNDERGROUND 6.1 General The long term performance of UPVC pressure pipelines is directly affected by the qualityof workmanship and materials used in installing the product. Competent supervision of all stages is important. In buried pipelines, the pipe and the soil form an integral structure. When installed properly, UPVC pipe gains strength due to the support of the soil. The soil and pipe wall deflect or compress depending on any one combination of the following three factors: a) b) c) Pipe stiffness, Soil stiffness, and Load on the pipe. INSTALLATION

4.3.13 Pipes should be stored away from any heat source and should not be in contact with any other potential hazards such as diesel oils, paints or solvents. 4.3.14 If PVC pipes are date coded at the time of manufacture, it is recommended to rotate stocks on a first-in-first-out basis. 5 STORAGE, PORTATON ANCILLARIES HANDLING OF FITTING!3, AND TRANSVALVES AND

5.1 Because UPVC fittings, valves and ancillaries are light and easy to handle, they are more likely to be mistreated than metallic components. Throughout all stages of storage, handling and transport they should be preserved from damage and contamination and be kept separate from and not temporarily jointed to the pipes until required for installation. When fittings are provided in packaged form, they should be retained in the individual package provided by the supplier, together with all associated rings, gaskets, nuts, bolts and accessories. 5.2 The impact resistance of UPVC fittings, valves and anti Ilaries is reduced in cold weather and more care needs to be taken when handling these products at temperatures below OO.If temperatures fall below 1 5, special instructions should be obtained from the manufacturer. 5.3 Fittings, valves and auxiliaries should be used in the order of delivery to ensure the correct rotation of stock. 5.4 Sealing rings should be stored in a cool place with temperatures not exceeding 35, preferably below 25. The seals should be protected from light, in particular strong sunlight and artificial light with a high ultra-

6.2 Trenching 6.2.1 Location Drinking water pipelines should not be located below sewerage pipelines.

FIG.

21 PROTECTION FROM SUNLIGHT 13

IS 7634 (Part 3) :2003 Where a pipeline runs parallel to other pipelines or cables, the distance between them should not be less than 0.4 m.
At points of congestion,

Table 2 Supported

Trench Width, Minimum

(Clause 6.2.2)
S1 No. Nominal Pipe Sizes (Diameter in mm) Trench Width Number of Pipe Diameters (Approximately) 14.2 12.0 10.0 8.2 7.2 6.4 5.6 5.0 4.5 4.2 3.5 3.1 3.1 2.85 Width mm 900 900 900 900 900 900 900 900 900 940 990 1040 1090 1 140

maintained contact. 5.2.2 Width

a distance of O.2 m should be unless steps are taken to prevent direct

Trenches should be of adequate width to allow the burial of pipe, while being as narrow as practical. If expansion and contraction are not problems and snaking of pipe is not required, minimum trench widths may be obtained by joining the pipe outside the trench and then lowering the piping into the trench after the testing. A trench width of two or three times the pipe diameter is a good rule of thumb. See Tables 1 and 2 for narrow (unsupported) and supported trench widths. Where necessary to prevent cave-ins, trench excavations in unstable soil shall be adequately supported. As backfill is placed and sheeting withdrawn, the void left by the withdrawn sheeting shall be filled and compacted before withdrawing the next increment. Table 1 Unsupported Narrow Trench Width, Minimum (Clause 6.2.2)
SI No.
Nominal Pipe Sizes (Diameter in mm) Trench Width Number of Pipe Diameters (Approximately) 7.1 6.0 5.0 4.0 4.0 3,9 3.5 3.2 3.0 2.8 2.4 2.25 2.1 1.9 Width mm 450 450 450 450 500 550 560 580 600 630 680 710 760 760

i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv)

63 75 90 110 125 140 160 180 200 225 280 315 355 400

6.2.4 Excavated Material Excavated material should be deposited at a sufficient distance away from the trench to prevent damage to the pipeline through falling stones or debris. 6.2.5 Soil The type of soil and the amount of compaction of the pipe embedment directly affect the performance of the pipeline. With proper embedment soil and compaction, greater burial depths are possible and higher external pressure capability and less pipe deflection will occur. 6.2.6 Minimum Cover should be followed: locate the pipeline

1) Ii) iii) Iv) \) VI) vii) \iii) ix) x) xi) kli) xiii) xiv)

63 75 90 I1O 125 140 160 180 200 225 280 315 355 400

The following guidelines a) b) c)

If frost is anticipated, below the frost line.

A minimum cover of 0.9 m when truck traffic is expected. A minimum cover of 1.8 m when heavy truck or locomotive traffic (dynamic loads) is expected. Usually pipe below 2.0 m of cover are not affected significantly by dynamic loads. If the application prevents deep burial of the pipe and heavy traffic passing over the pipe is expected, it would be advisable to use steel or reinforced concrete casing to prevent damage to the pipe. For high static and/or surcharge loads, it is important to use pipes of an appropriate stiffness in order to ensure the initial deformation of the pipe is maintained within a limit of 5 percent, maximum

6.2.3 Trench Bottom The trench bottom shall be constructed to provide a firm. stable and uniform support for the full length .of the pipeline. There should be no sharp objects that may cause point loading. Any large rocks, hard pan, or stones larger than 20 mm should be removed to permit a minimum bedding thickness of 100-150 mm under the pipe. For pipes of diameters 100 mm or greater, bell holes in the bedding, under each socket joint, shall be provided by removing some of the bedding material, to accommodate the larger diameter of the joint and to permit the joint to be made properly.
14

d)

IS 7634 (Part 3) :2003 6.2.7 Bedding and backfill by selection from as dug soils as free draining coarse friable nature, that is soils considered suitable. material may be available excavated material. -Such sand, gravel and soils of a which crumble easily, are 90 mm). In such cases, the thrust is the product of test pressure and annulus area:

where F P Di = thrust force; = test pressure; = inside diameter of the larger pipe; and

As dug material must be free from boulders, sharp stones, flints, lumps of clay or chalk. Contaminated soil and any organic material should be discarded. Where excavated material is not suitable, suitable imported material must be used. Prepare the bedding by laying on soft soil and alternatively compacting and watering sparingly until an effective thickness of 100 to 150 mm is achieved. 6.2.8 At the end of each working period, the pipeline should be temporarily capped to prevent the ingress of surface water, sand, dirt, debris and vermin. 6.3 Laying Lay the pipes in the trench after ensuring that bell holes have been provided for at the appropriate places in the bedding (pipes of diameter 110 mm or less, with no live load application, do not require bell holes in the trench bottom). These have to be refilled carefully after testing of the pipeline and prior 10 complete backfilling of the trench. Though not essential, the pipes should be laid with the spigots entered into the sockets in the same direction as the intended flow of water. 6.4 Anchoring 6.4.1 To sustain thrust caused by internal pressure, concrete anchor blocks should be provided at all changes of direction, tees, blank ends, large reductions in diameter and valves. The purpose of the anchor block is to transfer the total thrust to the trench sides. It is therefore important to take account of the load-bearing capacity of the surrounding ground (see Fig. 22). 6.4.2 Recommended mixture for concrete is one part cement, two parts washed sand and two parts gravel. 6.4.3 Where concrete would be in direct contact with the pipe or fittings, these should be wrapped with a compressible material, for example rubber sheet or foamed polyethylene sheet, to accommodate creep and prevent the occurrence of high local stress concentrations. The compressible material should not contain substances which could attack the pipe, for example plasticizers. 6.4.4 Typical thrusts generated are given in Table 3. Thrust forces on reducers need only be considered where the reduction in diameter is large (315 to
15

DC = outer diameter of the smaller pipe. 6.5 Backfilling 6.5.1 The first sidefill or haunching layer should be placed by hand and compacted in layers under the lower quadrants of the pipe upto the spring level (half the vertical diameter) of the pipe. Compaction can be done by carefhl trampling with the feet or with tamping tools. 6.5.2 Care should be taken to leave adequate area around the joint free of backfill to allow for inspection during testing of the pipeline. 6.5.3 Successive layers of backfill of 75 mm thickness may then be placed over and compacted to a height above the crown of not less than 150 mm. Light vibrating machinery may be used, but not directly above the pipe. 6.5.4 If imported granular, free-flowing material is used, this should be able to flow around the pipe and can easily be raked into position to form a complete, self-compacting surround. With carefully controlled pouring, the whole surround upto 150 mm above the crown may be placed in one pass. 6.5.5 Where side sheeting trench support has been used, this should be partiaily withdrawn during the placing of the side fill and surround, so that no voids are left between the pipe and the trench walls. 6.5.6 On completion of the surround to the pipe, suitable excavated material may be then replaced as backfill in 250 mm compacted layers upto the top of the trench. No heavy compaction equipment may be employed until there is at least 300 mm of fill above the crown of the pipe. 6.5.7 Metal marker tape can be laid into the final backfill to enable electronic location of the pipeline, if required. 7 ABOVE GROUND INSTALLATION

7.1 Since solvent cemented joints will sustain axial thrust caused by internal pressure (see 3.2), it is strongly recommended that UPVC pipes and fittings systems installed above ground or in service ducts constructed below ground are jointed by the solvent cement method. In certain circumstances the manufacturers advice should be considered. Other

IS 7634 (Part 3) :2003

1,41

)L--Jl

IMox. FORCE

1 L) (-

I
CONCRETE PROTECTIVE COVERING

-1

REDUCE RI Section) GROUNO LEVEL

RISER(SECTION)

FIG.

22 VARIOUS TYPES OF POURED CONCRETE ANCHORING 16

1S 7634 (Part 3) :2003 Table 3 Thrust Forces for Blank Ends and Bends (Clause 6.4.4)
S1 No. Nominal Diameter d. mm Thrust on Blank End (kNibar)) / 90 (1) (2) 63 75 90 110 125 140 160 180 200 225 250 280 315 355 400 450 500 560 630 (3) 0.31 0.44 0.64 0.95 1.23 1.54 2.01 2.54 3.14 3.98 4.91 6.16 7.79 9.90 12.57 15.90 19.63 24.63 31.17 (4) 0.44 0.62 0.90 I.34 1.74 2.18 2.84 3.60 4.44 5.62 6.94 8.71 11.02 14.00 17.77 22.49 27.77 34.83 44.08 Radial Thrust on Bends kN/bar of Various Angles (kN/bar)) 45 (5) 0.24 0.3 0.49 0.73 0.94 1.18 1.54 1.95 2.40 3.04 3.76 4.71 5.96 7.58 9.62 12.71 15.03 18.85 23.86 22.5 (6) 0.12 0.17 0.25 0.37 0.48 0.68 0.78 0.99 1.23 1.55 1.92 2.40 3.04 3.86 4.90 6.21 7.66 9.61 12.16

\ 11:25 (7) 0.06 0.09 0.12 0.19 0.24 0.30 0.39 0.50 0,62 0.78 0.96 1.12 1.53 1.94 2.46 3.12 3.85 4.83 6.11

1)
ii) l]i) Iv) v) v{) vii) \iii) lx) ~) xi) xii) xiii) xiv) xv) xvi) xvii) xviii) xix)

The values in the table are per bar of internal pressure,

//fi\\

//-j\

\//

EXCAVATED ~RfTNC~ ~,DT

PIPE ZONE HAUNCHING BEDDING

w
~~i;J.J.. . . ,>\:< . ,<

SIDE

FILL

-1.-

+1

-m
23 TERMINOLOGY OF TRENCH CROSS-SECTIONS 17

FOUNDATION (OpTIONAL)

FIG.

IS 7634 (Part 3) :2003 forms of end-load bearing joints are also acceptable in above ground installations. 7;5 UPVC pipes should not be restrained in the hoop direction by straps or clamps made from unyielding material. The use of a compressible material such as rubber of foamed pol yethylene between clamp and pipe is recommended. Pipes should be free to move in the longitudinal direction unless otherwise fixed for expansion contraction control. Recommended distances for horizontal support centres are given in Table 4. or vertical

for inclusion

7.2 UPVC pipes may fracture if fluids contained within the pipes are allowed to freeze. Sections which are likely to freeze should be isolated and drained, or insulation provided to prevent damage. 7.3 The coefficient of linear expansion of UPVC is approximately 60 x 10-6 m/m/C or 0.06 mm/m/C. The following equation is used for calculating the dimensional variation: AL= O.06LXAT where AL = variation in length, in mm, L Example: = initial length, in m, and For a temperature variation of 20C, a UPVC pipe 10 m long will have a variation in length crf O.06 x 10 x 20 = 12 mm AT = change in temperature of the pipe wall, in C.

7.6 UPVC pipes should be installed at sufficient distances from sources of heat to prevent damage due to radiant heat. 7.7 All control devices (such as valves) should be correctly supported so that the pipe is not subjected to any operational torsion strain. In addition, the support provided should be sufficiently robust to prevent bending and direct stresses being induced by the weight of the device. 7.8 UPVC pipes and fittings installed above ground should be protected from direct sunlight. 8 INSTALLATION IN-DUCTS

Where ambient temperatures are reasonably constant, the change in pipe wall temperature can be taken as being equal to the change in fluid temperature. Where this is not the case, the pipe manufacturers advice should be obtained. For length variations with temperature, Fig. 25. see Fig. 24 and

7.4 Pipes should be installed in such away as to ensure that the minimum amount of stress is induced in the system from movement caused by expansion/ contraction or any other forces. Examples of correct shown in Fig. 26. and incorrect installation are

Where possible, pipes with end-load bearing joints should be used for installation inside inaccessible ducts. In addition, rings should be fitted to the pipe to provide optimum support and to facilitate the withdrawal of the pipe in the event of rupture (see Fig. 27 for typical detail). For large diameter pipes, or where the duct is large compared to the pipe but not large enough to be accessible, other methods of securing the pipe maybe necessary (see Fig. 28). The opening between the pipes and the ducting system should be sealed at the ends. PVC Pipes

Table 4 Minimum

Supports for Unplasticised (Clause 7.5)

All dimensions in millimetres.

S1 No.

(}utside Diameter of Pipe de (2) 16 20 25 32 40 50 63 75 90 110 140 I 60 225 250

Distance Between Supporting Centres for Water at Temperatures Horizontal Pipes 20 c (3) 750 850 900 1000 1 100 1250 1400 1500 1650 1850 2150 2250 2500 2575 25 C (4) 670 770 820 920 1050 1200 I 350 I 450 I 600 1800 2100 2200 2450 2500 30 c (5) 600 700 750 850 1000 1150 I 300 1400 1550 1750 20s0 2150 2400 2450 35 c (6) 500 600 650 750 900 1050 1200 1300 1450 1650 I 950 2070 2320 2400 40 c (7) 400 500 550 650 800 950 1100 1200 1350 1550 I 850 2000 2250 2300 45 c (8)

Vertical Pipes 20 c to 45 c

(1)

(9) 800 900 1000 1200 I 400 1600 I 800 2000 2200 2400 2500 2500 2500 2500

1)
Ii) Iii) iv) v) vi) \,i]) \iii) ix) xl xi) xii) X111) xi\)

500 570 700 800 970 1070 1200 1370 1720 1850 2120 2200

18

VARIATION

IN LEN GTH, AL, mm

TEMPERATURE

DIFFER

EN CE, AT

l),i$-OF PIPE,
do ,mm

u ..

IS 7634 (Part 3) :2003

COMPRESSIBLE MEMBRANE

COMPRESSIBLE MEMBRANE

~J

,g

v
FIG. 26 CORRECT AND INCORRECT INSTALLATION

PIP E6EARING ON ROOF TRUSS

8.1 Installation ofpipes inaccessible ducts should be as described forabove ground installation under7.
9 TESTING

9.1.5 It is important to provide sufficient backfill over the main barrel of the pipe, to prevent displacement and to maintain stable temperature conditions. Leave joints free for inspection. 9.1.6 The test position should be located at the lowest point of the pipeline profile to encourage expulsion of air as the pipe is being filled with water. Adequate air release mechanisms should be located at all high points along the line. 9.1.7 Test-ends should be designed to enable the measured filling and subsequent emptying of the pipeline. Air bleed should also be incorporated at each end. 9.1.8 Pressurizing equipment should be adequately sized. Check all seals and non-return valves prior to the test. Pressure gauges should have an accuracy of + 0.2 bar. Automatic pressure recording equipment is recommended. 9.1.9 Before filling the pipeline, all line valves and air venting systems should be checked open. All air must be removed from the system. 9.1.10 Fill the system slowly. Water velocity must not exceed 0.6 m/s. Potable water pipelines should be tested with potable water only. After charging, close all air valves and check proper action of automatic valves.
20

WARNING : Pressure tests should never be carried out using compressed air or gasses. 9.1 Preparation
9.1.1 Pipe systems

should be hydraulically tested in lengths appropriate to the diameters and site conditions. Pipelines longer than 800 m may require testing in sections. Preferably, the length selected for test is between 300 m and 500 m.

9.1.2 Preferably, the test should be carried out between blank flanges (see Fig. 29). Testing against closed valves is not recommended, unless there is ho alternative.

9.1.3 Do not support the end pieces of the test section against the already laid pipes of the proceeding section. 9.1.4 Testing should not take place until any concrete used for anchoring has fully cured (normally 72 h) and attained its required strength. Solvent cemented joints must be allowed to harden for a minimum of 24 h before being subjected to test conditions.

IS 7634 (Part 3) :2003

TIMBER BRACING AND SUPPORT (SHORT DUCTS)

FIG.

27 TYP[CAL DETAILS OF PIPES INSTALLED IN SMALL DUCTS

~ MASS

CONCRETE

FIG. 28 TYPICAL DETAILS OF PIPES INTALLED IN LARGE 21

DUCTS

1S 7634 (Part 3) :2003

T(

m
/4
FIANG@ ADAPTEDTO SIZE ANOEND OF PIPE LINE UNDERTEST 14

II
T? //
o
68

0
o.

+
(9

29A Typical

Layout Details

for Test Ends

TEMPORARY THRUST WATERINLET FROM PRESSUREPUMP FLOW

Iw!g#ncl
FOAMSWAB BLANKFIJANGE OR TEST PIPE TAPPED TO SUIT PUMP CONNECTION

A
FOAMSWAB EMERGING FROM OND + CASTIRON DUCKFOOT BEND

=ORSAIR RELEASE CGCK I

BUNK FIANGE BOLTEDIN PLACE L

1
LOWPOINT HIGH POINT

29B Filling Behind a Form Swab

FIG.

29 PRESSURE TESTING OF INSTALLED PIPELINE

22

IS 7634 (Part 3) :2003 9.1.11 During filling, a number of movements will be seen in the pipeline. Allow the pipeline to stabilize under a nominal pressure for a minimum of 2 h. 9.2 Test PressureslJ 9.2.1 The test should conditions: a) b) c) conform to the following rhe volume of water added is an allowance made to :ompensate for the natural expansion/movement of the )ipe and flexible joints under pressure and for the 1 inevitable entrapment of small amounts of air within :he test length. In bubble form, this air compresses and may pass in and out of solution at test pressures.
I9.4.4

be carried out at ambient temperature; be applied for at least 1 h, but not more than 24 h; and not exceed 1.5 times the maximum rated pressure of the lowest rated component. the Test

On completion of any test, the residual pressure should be released slowly and in a carefully controlled manner.

WARNING: The rapid decompression of any entrained air may cause surge conditions which are potentially dangerous both to the pipeline and to personnel. 9.4.5 All defects revealed in the test should be rectified and the procedure repeated until a satisfactory result is obtained. 10 CORROS-ION PROTECTION soil

9.3 Applying

9.3.1 Allow the system to stabilize for 2 h after filling. Apply pressure steadily. Observe pressure gauges throughout and record the rates of pressure increase recorded. 9.3.2 The pressure should be increased till the specified pressure is reached at the lowest part of the section. Maintain test pressure at this level, by additional pumping if necessary, for a period of 1 h. 9.3.3 Close all valves and disconnect the pressurizing unit. No further water should be allowed to enter the system for a further period of 1 h. 9.3.4 During the test period, carry out a visual examination of all joints and exposed connections. 9.4 Interpretation of the Results

10.1 UPVC pipes are resistant to all normal conditions and require no corrosion protection.

10.2 UPVC pipe has a high resistance to chemicals and withstands attack by concentrated mineral acids (except nitric acid above 50 percent concentration), alkalis, oils aromatic free petrol and alcohols. However, UPVC pipes are sensitive to aromatic, or chlorinated hydrocarbons, nitro compounds, esters, ketones and strong oxidizing agents such as dry chlorine gas. 10.3 Where adjacent metallic parts are protected, no hot-or cold-applied coatings, or varnishes which contain solvents, should come in contact with UPVC. 10.4 Soil above and around the trench containing the pipeline sho-uld be protected from pollution through spilled aromatic hydrocarbons, paint, solvents, etc. 10.5 Anti-corrosion tape or similar protective materials applied to metal connecting pieces should be of a type which does not damage the UPVC pipes or fittings if they come into contact with the pipeline. 11 PRESSURE SURGE (WATER -HAMMER)

9.4.1 There should be no leakage in any part of the sec~ion. 9.4.21 f there has been a decrease in pressure during this period other than due to leakage, the original pressure is re-established by injecting a measured quantity of water into the section. 9.4.3 The test is considered
a)

to be satisfactory

ifl

there is no decrease in pressure (a slight rise in pressure is also, possible due to changes in ambient temperatures), the measured quantity of water required to reinstate the pressure to the original te-st pressure is less than the permissible maximum Q, where Q = 4.5 litres per 1.6 km per 25 mm of nominal bore per 30 m head of test pressure per 24 h.

b)

In operating conditions where surge pressures will occur, suitable precautions should be taken. In such circumstances, a surge analysis should be undertaken to establish the magnitude and frequency of surge pressure transients. Pressures greatly in excess of normal sustained operating pressures can be generated when fluid velocities change rapidly. The magnitude of pressure surge largely depends on the rate of-change of velocity and the modulus of the pipe material. 23

IIThe ~ccOmmefldcd ~e[ectiOn Of test pressure is eithe~ the nominal pressure PN of (he piping system (lowest PN of any component), or 1.5 times the actual operating pressure, whichever is greater.

IS 7634 (Part 3) :2003 Common causes of pressure surges are:

a) b) c) d) c) o opening and closing of valves,

each side so that the replacement length with doublesocket couplings on each end can be accommodated (see Fig. 30 and Fig.31 ). 12.1.2 Chamfer the ends of the pipeline reference marks on the ends. and put

starting and stopping of pumps, changes in turbine speeds, changes in reservoir elevation, liquid column separation, entrapped air. DAMAGED PIPE and

12 REPAIRING

For tbe replacement of damaged underground PVC pipe with a new pipe length, PVC double-socket couplings are available from the manufacturer. The rep]acemcnt can be done with a length of pipe with a spigot at each end and two double-socket repair couplings, also called slip-couplings (see Fig. 30), or a Icngth of socket pipe plus one double-socket repair coupling. In exposing the damaged area, enough of the line should be excavated so that the pipe can be flexed both to aid in handling the damaged area and to insert the replacement material, 12.1 Installing
-Double-Socket Each End a Replacement Section with a on

12.1.3 Determine the necessary length of the replacement pipe by measuring the gap dimension, multiplying it by 2, and subtracting the result from the length of the cut OUsection, as shown in Fig. 3 l(A). Cut the replacement pipe to the proper length and chamfer the ends. 12.1.4 Mount both the couplings on the ends so that they are in a position as shown in Fig. 31 (B). 12.1.5 Insert the replacement assembly in the line and slide the couplings into the proper position so that each coupling is centred over the gap [see Fig. 31 (C)]. 12.2 Installing a Replacement Section with a Length of Socket-Pipe and One Coupling 12.2.1 Carry out the necessary cutting and chamfering of the damaged area as per 12.1.2. 12.2.2 Mount the coupling on the cut and chamfered end of the replacement length. 12.2.3 .Complete the integral socket joint first by pushing the socket end onto the cut spigot end. 12.2.4 Slide the double-socket coupling onto the cut end of the line and centre it over the gap.

Repair Coupling (Slip-Coupling)

area. Ensure that cuts are square to the axis of the pipe. This area should include all tbc damaged area as well as include enough gap on

12.1.1 Cut out the damaged

~ PVC REPAIR

RUBBER

PVC PIPE CHAMFERED ENDS

FIG.

30 PVC DOUBLE-SOCKET REPAIR OR SLI+COUPLER (SCHEMATIC)

24

IS 7634 (Part 3) :2003

31A

Faulty Joint Cut Out and Pipe Ends Chamfered

..

--

31B

Slip-Couplers

Positioned

with Make up Pipes in Position

6 . - . .. - . - -

31C Slip-Couplers

Moved into Position

and Make up Piece

FIG. 31 REPAIRS USING DOUE3LE-SOCKEr REPAIR COUPLERS

25

IS 7634 (Part 3) :2003

ANNEX A
(Foreword)
COMMITTEE COMPOSITION CED 50
Representative(s) S~RI K. PRABHAKAR RAO (Chairman) SHRI N. P. PAT~L SHRI V. B. PARMAR (Alternate) HYORAULIC ENGINEER DEPUTYHYDRAULIC ENGINEER (Alternate)
SHRI J. SEN GLJPTA SHIU D. K. SANYAL SHRJA. K. BISWAS (Alternate)

Plastic Piping System Sectional Committee,

Ozga}iization
Engineer-in-Chief3s Branch, Army Headquarter, New Delhi

Ahrnedabad

Municipal Cmporation, Mahanagar

Ahmedabad

Brihamnurnbai

Palika, Mumbai Promotion Council, New Delhi

Building Materials and Technology Calcutta Municipal Corporation,

Kolkata

Carbon Everflow Limited, Naslrik Central Building Research Institute, Roorkee Central Institute of Plastic Engineering Central Public New Delhi Health Envirmrment Technology, Bhopal/Lucknow Organization,

Ms SEEMAVAIOYA SHRJB. M. VALASKAR (Alternate) SHRI L. K. AGGARWAL SFIRJSURESHKUMAR SHARMA (Aherna[e) DR VIJAY KUMAR DR SANJAAKHTAR(Alternate) AOWSER(PHE) ASSISTANT ADVISER (PHE) (Aherna[e) CHIEFENGINEER (D.ESIGN) SULI~RJNT~NIXNG ENGINEER (S&S) (Akma/e) SHKIR. N. SURIYA NARAYAN SINGH THIRUV. SWAKUMARAN (Alternate) DIRFCTOR (MATERIALS MANAGEMENT) SUPERINTENDING ENGINEER (DESIGN)(A//ernate) SHRJ S. K. CHHABRA
SHRI L. N. KAPOOR(Ahernate)

Engineering

Central Public Works Department, Chenn~i Meuwpolitan Delhi Development

New Delhi

Water Supply and Sewerage Board, Chennai

Authority, New Delhi

Dell?] Jal Board, New Delhi Department Directorate of Telecommunications, New Delhi Mumbai/Patna New Delhi

SHRI SURINDERNATH SHRI A. K. NAGAR (Alternate)

General of Supplies and Disposals, Branch, Army Headquarter,

SHFOA. K. JAIN SHRI A. K. M. KASHYAP (Alternate) SHRJR. A. DUBEY

SHRI AJAY SHANKAR(Alternate)

Engineer-In-Chiefs

EPC Industries Pvt Limited, Nashik Finolex Industries Limited, pune Huusing and Urban Development Institute of Co-operative Corporation Limited, New Delhi

SHP.IK. L. KHANNA SHRJVINAYAK V. SHEMBLKAR (Alterna/e)

RAU DR DHANANJAY

SHRI K. SUBRAMANIAN SHRI P. R. SRIVASTAVA (Alternate) DR S. M. PATEL DR M. K. PANDEY (Alternate) DR H. C. MRUTHYUNJAYA SHRI S. NARAYANASWAMY (Alternate)
MLNT UNIT) DEPUTY CHIEFENGINEERING (MATERIAL MA~AC,I

Management,

Ahmedabad

Jain Irrigation Systems Limited, Jalgaon Kerala Water Authority, Thiruvananthapuram KWH Pipe India Limited, Raigad Mahanagar Telephone National Environmental Nigam Limited, New Delhi Engineering -Research Institute, Nagpur

SHRI S. SUNDRAM SHRJP. V. KULKARNI (Alternate)

SHRI S. B. LAL SHIU A. K. NAGAR (Ahernate)

DR M. V. NANOTI DR S. P. PAND~(Alternate)

(Con[itraed on page 27)

26

IS 7634 (Part 3) :2003

(Continuedf.om page 26) Representative(s) SHIU R. K. BHATIA SHRI A. R. PARASURAMAN (Alternate) Bhubaneswar RooIkee
Department, Jaipul

Organization NOCIL Limited, Thane Public Health Engineering, Public Health Engineering,
Public Health Engineering

SHRI P. C. MAHAPATRA SHIUG. C. PATRA(Alternate) SHRI SUDESH KUMARSHARMA SUPERINTENDING ENGINEER EXECUTIVE Eiwmmm (Alternate) SHRI GULAMAHMED SHRI SUBHASH SANZGUO SHRI V. B. RAMARAO (Alternate) SHRt C. K. SHARMA SHRI G. K. SAXENA SHRI WILLIAMHANODNES (Alternate) JOINTCHIEFENGINEER (CONTRACT) ENGINEERING DIRECTOR (Alternate) MATEIUALS MANAGER CHIEFENGINEER (PPR&D) MANAGING DIRECTOR SHRI G. K. SRINIVASAN SHRI P. SAI VENXATA PRASAD (Aherna/c) SHFOO. P. RATRA SHRI KANWAR A. SINGH SHRI S. K. JAIN, Director and Head (CED)
[Representing Director General (Er-oficio)]

Public Health Engineering Reliance Industries Limited,

Department, Mumbai

Bangalore

RITES, New Delhi Supreme Industries Limited, Jalgaon Tamil Nadu Water Supply and Drainage Board, Cbennai L1. P Jal Nigam, Lucknow
Uniplas India Limited, New Delhi

(Alternate)

Vinplex India P\t Limited, Cbennai

{n personal capacity (C-478B,

Sushant Lok Phase 1, Gurgaon)

In personal capacity (196 Grdmohar Park, New Delhi 110 049) B[S Directorate General

Member Secreteraries SHRI J. K. PRASAD Director (CED), BIS and SHRI R. K. GUVTA Joint Director (CED), BIS

PVC and ABS Piping System Subcommittee,

Vinplex India Pvt Limited, Chennai
All India PVC Pipe Manufacturers Association, New Delhi

CED 50:3

SHru G. K. SFGNIVASAN (Converser) SHRI P. SAIVANXATA PRASAD (Alternaie) SHRt S. S. GUPTA SHRI DEEPAKPODDAR SHRI L. N. PODDAR (Ahernafe)

AshHvad Enterprises, Brihanmurnbai

Patna Palika, Mumbai

Bhopal

Mahanagar

HYORAULIC ENGINEER DEPUTYHYDRAULIC ENGINEER (Alternate) DR VOAIKUMAR DR SANIAAKHTAR(,41ternafe) CHIEFENGINEER (CSQ) EXECUTIVE ENGINEER (S&S) (Alternate) ENGINEER-IN-CHIEF (W) SHRI S. K. CH.AiDHA (Alternate) SHRI M. C. GOEL

Central Institute of Plastic Engineering and Technology,

Central Public Works Department, Delhi Jal Board. New Delhi Delhi Test House, New Delhi Department of Telecommunications,

New Delhi

New Delhi

SHRI V. L. VENKATARAMAN SHRt P. ADINARAYANA (Alternate)

(Continued

on page 28)

27

IS 7634 (Part 3) :2003

(Canii)fued from page 27) CJrganization Directorate General of Supplies and Disposals, KolkataiNew Delhi Representative(s) SHRI RAJFNDER PKASAD SHRIN. K. KAUSHAL (Alternate) DR DHANANJAY RAU SHRJV. V. KANOEKAR (Ahernaie)
SHRJS. NARAYANASWAMY

Finolex Industries Limited, Pune Jain Irrigation Systems Limited, JdgrsOn Mahanagar Telephone Nigam Limited, New Delhi
Industries Limited, Thane

SHRJL. JAGANNATHAN (Alterrrate) SHRJ S. K. CHADHA SHRJM. K. SI~GHAL(Alternate)

SHRI P. K. BHATIA

Na(tonal Organic Chemical

SHRJM. M. SHAH (Alternate) Reliance Industries Limited, Mumbai

Rex Polyextrusion RITES, New Delhi Limited, Sangli

DR S. M. DIWAN SHRJM. V. PRASAD(Alternate) SHRICHANDERSEKHAR SHRJC. K. .%ARMA DEPUTY CHIEF INSPECTOR ENGINEER (Alternate) SHRI W. MANDONCA SHRJG. K. SAXENA (Alternate) ENGINEER-IN-CHIEF JoIrw CHJEFENGINEER (MATERJAL) (Alternate) SHIU P. M. HARJNATJi DEPUTYDIXECTOR (CR) (Alternate) SHRJS. N. JHA SHIUM. K. SRJVASTAVA (Alternate) SHRI O. P. RATRA SHRI KANWAR A. S[NGH

Supreme Industries, Jalgaon

Tamil Nadu Water Supply and Drainage Board, Chennai

Tamil Nadu Water Supply and Sewage Board, Chennai

Telecommunications Consultants India Limited, New Delhi

In personal capacity (C-478B,

In personal

Sushant Lok Phase 1, Gurgaon)

capacity (196 Gulmohar Park, New Delhi 110 049)

28

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